Wire rope and machine for and method of making



April .14,1936- M. G. ENslNGR Erm. I 2,037,506

WIRE ROPE AND n aAcHINE FOR 'AND ,METHOD oF MAKING originall Filed Jan. 6, 1927 '2 sheets-sheet 1 @15 @atom g April 14, 1.936..

M. G, ENslNGr-:R Er AL WIRE AND MACHINE FOR ND METHOD OF MAKI original Filed Jan. e 15927 a sheets-shea' 2 Patented Apr.. 14, 1936 I QNITED l 'nora AND MACHINE Foa AND METHOD oF Minime PATENT OFFICE Mahlon G. Ensinger, Tulsa, Ogle., and 'Walter Voigtlander, Kansas City, Mo., assignors, by

direct and mesne assignments, to American Cable Company, Incg a corporation of Delaware Application January 6, 1927, Serial No. 159,261 Renewed October 22, 1935 25 claims. (ci. 111-59) This invention relates toimprovements in the art of wire rope, which name commonly de fines vthe strong, die-squeezed compacted metallic-wire rope structures in general industrial use for heavy duty as inthe-mining, logging and oilA industries, in general construction includingbridges, hoisting, conveying andvNmarine operations, and in industrial plants generally, etc., the wire rope construction for suchsuses principally consisting of a wire rope including a plurality of metallic wire strands or outerpelements extendingin helices a'round a central element commonly called the "core or center of the wire rope structure, the assembly of strands (outer elements) and core (center) as a whole -possessing the high longitudinal resilience necessary for momentary longitudinal rope-yielding to abrupt applications of the heavy service loads and consequent avoidance of rope-breakage thereby; the strands commonly numbering six; each strand consisting of a plurality of metallic wires commonly of steel and commonly numbering eighteen stranded together in helices inlayers around their'own central element, which-comspringiness of the individual wire helices. Gen- 4 erally in wire rope there is a center or core com'- prising fibrous material for the purposeof increasing the longitudinal rope-resilience and also of increasing the rope-flexibility; and commonly such fibrous core consists of ordinary commercial so-called-"hemp rope consisting of vegetal bers suchas manila, jute, sisal, cotton,- etc., and

.occurrence of so-called rope-faults of various kinds during either or both pre-.installation handling or during service under the heavy loads;

such 'faults develop into injuries during the heavy service, and such injuries shorten rope-life by causing premature breakage and meanwhile reduce safetyduring service. The various ropefaults to which wire rope structures are subject are caused either. or both by (l) excessive tendencies of the strands d handling to spring into di lacements constituting the faultsf i. e., lack o! inertness, or by (2) lack oi' equi-stress or balanced relations of strands and core which, during the 'heavy service gior which wire rope structures otherwise are well adapted, results in vconcentration of excessive proportions of the heavy service loads upon one or moreof 'the strands or on the c ore, so that vcore and strands cannot properly cooperate in the Lsense that each shares properly with the others in sustaining the 'service loads, the result ing pre-nistaiitmnf being rope-faults and prematurerope-breakage. 'Y

According to the invention novel wire rope structures are produced which possess the adlvantages and lack the disadvantages above set forth. 'The products are inert in the sense that they are in a condition substantially free from internal stresses which cause or tend to cause the helical wires. or strands, when not tied together,v to depart from the. shapes and positions proper in ideal structures, and in character the products are substantially dead-lay, inert-lay, stress-free and neutralized. In addition, the

helical outer elements and the center element or core all are in balanced stress relation with one another, so that each shares properly with all ,the others in sustaining service loads, and thev wire rope' structures possessing said character- 1st1cs of mertness and balanced relations also are capable ofv long resilient service life.

According to the invention, such novel wire previously assembled wire rope structure, tensioning stresses of lcertain magnitudes sufiicientlyv but not excessivelyhigh ais-hereinafter defined.

tensioning stresses preferably are applied to each successive portion of thev length of the assembly as it travelsfrom the squeezing closing die to thewind-up reel, and preferably in a series of steps of progressively increasing magnitudes of tensioning; and also, for eifecting balancing, in addition .to inertness, the series of tensioning steps preferablyv isemployed with a corresponding series of flexings of the assembled wire rope structure as a whole. In any case the tensioning treatment preferably is applied to the assembly in such Way that it does not affect the stresses acting on thev squeezing' closing die wherein the elements are assembled, and in such YTo effect balancing, in addition to inertness, these Iway that it vcausesl the application` of stresses to the individual helical wire outer elements whichto be by the tensioning compressed against center or core. Thus, with the result of producing equistress or balanced relations of all the elements, the tensioning of the helical outer elements tends to equalize the strand-lays relative to one another and With respect to the center; and, with the result af imparting a metal-set deformation to the helices producing effective inertness, the compression of the helices against the centercaused by the tensioning, reacts with the radial resistance of the center to such compression'during the continued tensioning of the helices, so as to stress the metallic helices beyond their elastic limits into the desired' substantially inert conditionlacking excessive springlness. For the purpose of producing balanced relations, in addition to inert condition, irl a wire rope having a center or core of the fibrous or hemp-rope type, the employment of a plurality of successive flexings of the assembly in connection with the series of tensionings of progressively increasing magnitude, is particularly useful for several reasons, (l) the ilexings are particularly effective in causing shifting movements of the helical strands from non-balanced into balanced relations, (2) the initial` less heavy stressings of the series cause the strand-helices togbe less heavily com- 'pressed against the core and therefore preserve comparative freedomv of the strand-helices for their shifting balancing movements caused by the flexings and tensionings, (3) the initial radial yieldability of the hemp-rope type core cooperates with the initial less heavy stressings in preserving said freedom of the strand-helices for balancing movements, and (4) in the later, heavier stressings of the series, the desired metalset deformation of the strand-helices into inert conditions is' effected by the then more powerful internal reactions between strands and core at a'time lafter the balancing has been substantially effected by the earlier less heavy stressings of the series, so that the later more substantial deformation does not interfere with the earlier more substantial balancing; the internal reactions which cause the more substantial deformation being caused by the later, heavier stressings as the result of the then-existing greater radial resistance by the more highly compressed and dense fiber core to the increasing compression Vagainst lsuch core by the strands under the then higher tensionings. The result of the serial treatment in any case is to produce better relations of balance than can be produced by a single tensioning of the assembly of suilcient magnitude to produce optimum deformation to inertness. 'I'he result of the serial treatment which includes the multi-flexing is to produce better relations of balance in a wire rope having a fiber or hemp-type core than can be produced, in the lack of multi-flexing, even by a series of tensionings of progressively increasing magnitude. The relative extents of balancing and deformation in a given product are dependent upon the previous condition of the assembly subjected to the processing; but in any form of the processing the balancing and deforming operations are substantially simultaneous so thatin any form of the product the conditions which cause inertness are also the cause of the setting of the balanced stress relations into the product as a permanent characteristic thereof.

In addition to the process, the invention includes also the novel wire rope possessing the characteristics described herein, and the novel' arrangements of apparatus units employed in the processing.

In the novel arrangements of apparatus units, the several units as individuals may be employed in the forms heretofore employed in the wire rope industry.

The best examples of the invention known to us are illustrated by the drawings, some of which are more or less diagrammatic for the purpose of most clearly explaining the principles of the' invention by simple and clear illustrations not confused by relatively unimportant details.

Fig. 1 is a diagram of one exemplification of the processing and of the apparatus; Fig. 2 a drawing in transverse section of a preferred form of thel various forms of the new product and consisting here of a wire rope comprising radially yielding center or core of hemp, jute, manila, or the like vegetal fibre;I Fig. 3 a sketch illustrating the novel metal-set strand-deformation or inert or dead-lay strand-construction resulting from the processing; Fig. 4 a sketch in transverse section illustrating the initial corecondition of the preferred radially yielding core of Fig. 2 previous to' processing of the assembled wire rope which results in the product of Fig. 2; Fig. 5 a sketch in like section of the same radially yielding core showing it separately in the same condition as in Fig. 2 after processing of the assembled rope including such core; Fig. 6 a sketch in like section of the same radially yielding core illustrating its condition without injury after long service of the rope including it, but the core being resiliently dead as the result of long service under the heavy loads; Fig. 7 an elevation of the wire rope of Fig. 2 also illustrating its good condition without rope-faults or injuries after having been handled previous to installation for service, and after a long life of heavy-duty service; Fig. 8 another form of our novel product similar to that of Fig. 2 save for having acore of initially smaller diameter than the core of Fig. 4 in the rope of Fig. 2 before the processing hereof; Fig. 9 a diagram supplementing Fig. 3 and illustrating more clearly the nature of the novel metal-set strand-deformation or inert strand-construction resulting from the processing; and Fig. 10 a diagram exemplifying the principles of the processing in a different form, and the novel arrangements of apparatus units therefor.

Fig. 10, left, at lay-plate LP and closing or squeezing die CD, illustrates the preferred initial processing hereof which is the well-known previous commercial assembling and die-squeezing method of producing wire rope structures in general.

An excellent example of the balancing and del forming processing of assembled wire rope structures is shown in Fig. 1 between CD and POI where POI is any suitable power-driven pull-out or draw-off drum, as used in the wire rope art to pull the wire rope structure in process out of CD. Here POI is driven with sufficient power to pull the wire rope structure, not only through squeezing die CD but also around a plurality of sheaves I, 2, 3, of diameters small relative to POI in substantially the proportions shown, and to pull individually the strands S o-f wires W and core R for a wire rope from their reels at left (not shown) and through lay-plate LP. Each portion of the length of the rather stiff wire rope being pulled by POI from CD and around the successive relatively small sheaves, thereby is powerfully exed a plurality of times ancing and deforming aosvoe.

in relatively sharp bending angles by the tensionings on the rope by power from POI, so that each such portion of the rope-length is subjected repeatedly to powerful flexing stresses under the successive tensionings; and the simultaneous balactionson strands and core are progressive. 'I'he presence of vegetal ber core R, Fig. 4, in the -assembled rope being processed, imparts the sufficient flexibility o'tle stiil.' and otherwise much stiffer wire rope w ch is necessary to permit its said relatively sharp-angled exings. The relatively small sheaves are mutuallyoil'set as shown, so that successive sharpangled ilexings of the assembled. wire rope are in opposite directions. In order to pull the ropeassembly not only through-CD but also around the successive sheaves I, 2, 3, in the above relatively sharp flexings around the relatively small sheaves, the drum POI is driven with greater power than when there are no flexings as in Fig. 10, other conditions being equal. The result is that in Fig. l the tensioning on the rope-assem- Ibly passing from the last sheave 3, ,to POI, is

substantially higher than that in Fig. 10 between CD and POI; and correspondingly, since in Fig. 1 a portion of the greater power of POI in Fig. 1 than in Fig. 10, is usefully consumed in the successive flexings in the direction from POI toward CD, the tensioning between the flexings at 2 and 3 causing the flexing at 2, is lower than between 3 and POI; the tensioning between I and 2 and causing the flexing at I, is lower than y between 2 and 3; and the tensioning between CD and I and causing the assembly to be pulled through CD, is the lowest of the 'series of tensionings acting between CD and POI. spondingly, since such tensionings provide the Apower for the respective powerful flexings, the

flexing or bending stresses of the series in the direction from POI to CD likewise are of progressively decreasing magnitude, other things being equal. That is, in the opposite direction, which is the direction of rope-travel, l(see arrow), all the stressings of the series, both tensionings andilexings, are ofprogressively increasing magnitude, other conditions being equal. The result is that each portion of the length of the ropeassembly traveling from CD to POI is subjected successively to a plurality of flexing and tensioning stresses of progressively increasing magnitude. An object and result of this is the avoidance of such premature deformation of strands or core by tensionings during the earlier, less heavy stressings as would antagonize or oppose the desired balancing action during the earlier- 'the balancing and permanent deformation. The

stressing' at each of the successive flexings is made. sufllciently powerful by the combination of the relativelylong rope-arcs involved in each flexing, with the relatively sharp'angles of exing; the long rope-arcs being caused by the offset relations of lthe sheaves, and the relatively sharp flexing-angles being causedA by the relatively small diameters of the sheaves; one result being that theflexed rope-portions' are subjected to stresses which are more powerful than those acting in squeezer CD; and another result being a diierent kind of stressing of the flexed Corre.- i

rope-portions than the stressingv inside CD, as follows. At each flexing, the strands of the flexed rope-portions are bent at relatively sharp angles to the relatively abrupt contour of the relatively` small'sheave; and this operation involves subjection ofthe core to powerful compression by the strands, and also involves powerful tensioning ofthe flexed strands during the time of such core-compression by the strands. It is this combination of core-compression by the strands and simultaneous strand-tensioning during the core-compression, all during the flexing of the assembly, which produces the balancing and deforming operations respectively but simultaneously. The" tensioning of the strands on the outer or convex portionsl of the iiexure is higher than durlngthe axial tensionings between successive ilexings around successiveA sheaves.

The tensioning of the strands on the inner or on the outer or convex portion of the flexed assembly. The offsetting of the successive sheaves however causes flexing in successively opposite directions, so that in thevsuccessive fiexings the strands lying adjacent each side of the core successively lie on the vouter or convex side of the flexing. The eilect of the progressively increasing magnitude of the stresses in the successive ilexings is progressively to increase the cc-resuch strands which in a given flexing extend compression or density by the strands and to..

increase the strand-tensioning at the flexed portions being compressed vagainst the core. As these stresses increase, the increasing resistance of the increasingly dense center or core to the increased strand-compression against it causes the strands to be deformed beyond their elastic limits by the increasing tensioning on them at their flexed portions, into strand-,helices of larger and larger metal-set diameters as the successive stresses increase progressively in magnitude. This metal-set deformation of the plurality of strands in the assembly, at each flexing and under the effect of tensioning during flexure, is generally analogous to the action involved in making a wire spring by tensioning a resilient vmetallic wire while bending it around a man- Here, however, as the compressions by the flexed strands on the core and the tensioning on drel.

such flexed strands, are increased in the successive ilexings, all the plurality of strands progressively are stressed again and again beyond their elastic limits into metal-set helices of larger and larger diameter. These permanent stranddeformations into helices of permanentlyla'rger diameter take place while the helices temporarily are being' stretched into temporary smaller diameter.

While the strands thus are being deformed into new. shapes by the successive ilexings of the assembly, they also are being shifted simultaneously into new adjusted positions of equi-stress or balanced relation with one another and with the core. All ordinary wire rope having a commercial .hemprope ofilbrous or vegetall core is `subject to non-balanced relations because of the irregularities along its length including varying diameters. The formation of the strandhelices, without substantial deformation, in the squeezer CD, While the strands are being assembled around the core, puts the strands in out-ofbaianee relations with one another. For the purpose of producing balanced stress relations during the operation of deforming the strands while in the assembly, we have found that the above multi-flexing treatment is especially advantageous when the assembly includes a core of the commercial hemp-rope type which heretofore has been the cause of non-balanced relations. The advantage of this application of the multiflexing process to an assembled wire rope being a hemprope type core is thatsuch a core initially possesses radial yieldability to the earlier,

less heavy strand-compressions in the' earlier flexings, so that thereby there is less powerful binding of strands against core, the result being that the strands during the earlier flexings are relatively free for the relative shifting strandmovements which are involved in the balancing operation; and yet, during the later flexings, under the then heavier strand-compressions on core caused Iby the heavier tensionings on the exed strand-portions, the core-resistance to such strand-compression is suiiicient to cause deformation of the strands while they are positioned in their balanced relations. Thus, previous to such strand-deformation as otherwise would prevent desired balancing, the desired baiancing is eiec'ted by the earlier exings under less core-compression by exed strands and less strand-tensioning during flexing, and while the core, previous `to the later heavier compression by the strands, yet is more yieldable radially to the lighter strand-compressions thereby allowing strand-movements to balanced relations under the balancing stresses of the flexings. In the balancing operation the slack in any strand or strands in the assembly is in effect ironed out backward (leftward, Fig. 1) towardY CD, thereby removing a large part of the discrepancies between length of strand-lays and to that extent putting the strands in balanced relations with one another. This ironing out of strandslacks involves arresting the same between CD and the first iiexing at I, thereby preventing travel of strand-slacks with the wire rope rightwardly beyond l; the non-slack strands in the traveling assembled rope in eii'ect catching-up with the strand or strands of which the slacks are being arrested. This ironing operation is the effect of the lighter earlier iiexings, acting on the assembly having a center or core which rradially yields at such time so as to permit the strand-slack ironing movements which the ilexings tend to cause. The other adjusting or shifting relative strand movements also occur during the multi-flexing as the result of the radial yielding of the core to its compression by the strands during the increasing strand-compressions in the successive exings. pressions form grooves in the core of progressively increasing depth, so that the strands move bre-adside or laterally further and further toward the center of the core, thereby further improving the balanced relations of strands relative to one another and improving the relations of strands relative to the irregularities of the commercial hemp-rope or iiber core. The successively opposite iexings of progressively increasing strandcompression on the core cause the strands to be worked deeper and deeper into the core and -constitute an effective kneading operation co- The increasing strand-comly smaller diameter and the helical core-grooves receiving the strands become permanently deformed into progressively increasing depths, as at GG, Fig. 5, with extruded core-projections P, all as distinguished from the initial core condition in Fig. 4. The resulting increase oi' coredensity caused by the processing is illustrated by the greater core-,density in Fig. 5 than in Fig. 4. This permanently deformed dense core condition is advantageous in several respects. The radial core-projection P, while not excessively long, nevertheless extends suiliciently far into the inter-strand spaces to support the strands in spaced-apart condition preventing strand-to-strand contacts and thereby providing for rope-pliability. Also the great core-density permits substantial increase ofl resilient core life and therefore resilient rope-life in. that it permits the use oi a core of larger initial diameter than heretofore has been practicable in an ordinary type wire rope of given diameter, because in the lack of the permanent core density as in Figs. 5 and 2 and 8 as compared with Fig. 4, the higher radial resilience of a larger core tended to push the strands away and increase the susceptibility to pre-installation faults; but in the preferred form of Fig. 2, with initially larger core R than the initial diameter of core Ri of Fig. 8, the initially larger core can be used without such disadvantage because of the effect of the deeper grooves GG coupled with the deformed strand-helices EV to be described, whereby the inert characteristic of the product isobtained, all with the result that the resilient life of the product can be increased by the use of the larger core. This is illustrated in Figs. 2 and 8 which show the same wire rope save for the initially larger core R in Fig. 2, illustrated here by the denser stippling of core R in Fig. 2 than that of core Rl in Fig. 8, the denser stippling in Fig. 2 illustrating the denser condition of larger core R than of .smaller core RI in Fig. 8. That is, the two completed wire rope products of Figs. 2 and 8 are of the same outside diameterfbut the assembly in Fig. 2 with initially larger core has been subjected to higher processing stresses than that in Fig. 8 with the results that the coregrooves are deeper and that the higher strandcompressions on the initially larger core R of Fig. 2, in addition te the deeper seats of the strands in the deeper grooves, have so reduced the effective diameter of the core that the wire rope of Fig. 2 has substantially the same outside diameter as the wire rope of Fig. 8 having the initially smaller core; although the greater mass oi longitudinally resilient core-material in Fig. 2 causes longer life of the product of Fig. 2 than of the product of Fig. 8. In a wire rope having a total diameter of one inch and a 'fiber core of half inch diameter, an increase of core diameter oi' only a thirty-second of an inch will increase the life of the wire rope substantially, and that is permitted by the invention.

The principal advantage, however, oi the eompressibility of the fiber core by the strand-compressions in the multi-flexing treatment, is that of the increasing radial resistance of the core as its. density is increased by the increasing strand-compressions in the successive ilexings; for it is the increased radial resistance o1' the side the wire rope which stresses the strands beyond their elastic limits and deforms them into metal-set helicesA of larger and larger diameter simultaneous with the above progressive balancing movements .of the stran s during the multiflexing; for in the case of an center or core, the

greater the radial core-resistance to strand comstrands and core during the multi-flexing .pression and the greater vthe strand-tensioning during great radial core-resistance to strandcompression, the greater will be the stranddeformation to helices-of larger diameter. o

Simultaneously with the above deformat on of ment of the assembly having a vegetal or ber core for'the purpose ofA most effective utilization of 1 the flexing stresses for the lpurpose of f eifecting'balancing, theebalancing-operation is taking place preferably under'the 'following conl ditionsl as shown. The first flexing of a' given portion of the wire rope 'assemblyis at I where the core-compression by the strands and thetensioning ofthe strands `at the place of flexure are thelowestbetween CD and POI, so that,

thereby there is avoided initially all heavier rlstressing such as later at 2 or 3 which if so applied at I nearer CD mightl cause undesirableA alteration ofy the uniformity of critical assembling stresses acting inside CD and undesirable alteration of the effect of the stresses .in CD in producing uniformity of strand-lays. By -this arrangement th assembling operations inside CD cannot be affected by the later, heavier stresses of the series by which is effected the deformation of strands and core; the initial balancing operations being conducted under axial tensionings of the wire rope between sheaves which are not,

muchv greater than the tensionings in CD, and being conducted intermediate the assembling in CD and the deformation by the` later stressings after the first flexing at I'. As shown also, the first fiexing at I preferably is produced as close as practicable to CD, the advantages of this being two; first, the ordinary 'type in Vits condition of emergence from CD possesses minimum deformation of strands and core and therefore there is minimum opposition to the exing stresses causing the ironing out of strand-slacks, and second, the first flexing at I, close to CD, is produced before any prolongedrope-tensioning between vCD and flexing I which would cause deformation opposing the ironing action of the flexings. As shown also in Fig. 1, the sheave-set as a whole is located closer to CD than to POI so as to complete the balancing and; deformation by the series of i'lexings on each portion of the length of the assembled rope as soon as practicable after its emergence from CD and before the rope finally is subjected to any prolonged or high axial tensioning as between 3 and POI which is the highest between CD and POI and useful in reflecting further deformation after completion of balancing by the flexings and partial deformation.

' Preferably the wire rope which is processed hereby, for most effective strand-shifting balancing'action is of the ordinaryl type, wherein, as shown at left, Figs. 1 and 10, the strands S are pulled" in straight condition to CD without any deformation of individual strands or core previous to assembly, as'of strands inthe "pre-formed" type, and with only slight if anydeformation o! strands or core by CD wherein the straight strands entering CD are bent laterally, without substantial metal-set 'deformation into helices around the coreand preferably therein squeezed by CD into as compact an assembly with thecore as is practicablev without injuring the outer wires i of the strands traveling in contact with the usual hardened steel walll oi' die CD. A wire rope in such initially compact condition is well adapted to be balanced by the processing hereof, because of its possession of minimum deformation oi.' strands or corel interfering with the relative shiftirgbalancing movements ofthe strandsv whichtheprocessing stresses can and do produce nl'ess there be premature excessive deformations oi' strands or coresasby excessive strand' predeformation in advance of assemblage-in CD as in'the case of the pre-.formed'typef as heretofore produced with strands pre-deformed. substan-l tially to core-dia eter. The ordinary type in said sense also is'well adapted to be balanced by the processing hereof because the'st'rands at the time ,of processing of the assemblyalready are in place around the core, so that the balancing o f the strands relative to one another is effected with reference to the core around which theyalready are assembled as distinguished from the pre-formed typeY wherein the strands previous tov assemblage individually and separately are given metal-set deformationsto predetermined like diameters so large as to approximate the are to beassembled, as at B, Fig. 9'. Furthermore, commercial hemp rope employed as the core of wire rope, possesses'irregularities including varying diameters along its length. By the Aapplication oi' the flexing stresses hereof to an i assembled, wire rope preferably having no predeformation lof strands and in no case having excessive strand-deformation, the strands are put in balancedrelations with the core during a time when 'the strands extend aroundthe very core with relation to which balancing is desired,

and during the time while the strands arebeiiigput in balanced relations with one another; and by the application of the processingy flexing stresses' to a wire rope assembly, suchas the diameter -of 'the core around which they later cession is an axial' tensioning of greater magni- POI, Fig. 1), for the purpose of obtaininggreaterv deformation fof strands and core; P02/being, as POI may be, any desired\wireropef pulleout -or draw-off drum, but P02y being so power-driven as to exert a more powerful pull than POI, Fig. 10, on the assembled wirerope structure. In forms of the process `wherein the greater axial tensioning by P02 is employed, the multi-flexing treatment by the set of re atively small sheaves may be executed under such gher rope-tensioning as by P02; but that is not pref ed because such higher tensioning, acting to ffeet great strand-deformation, would oppose the bestbalancing operation by the multi-flexing, which as shown is most effective under the lower although powerful tensionings in Fig. 1 betweenA CD and POI. Preferably, as shown in Fig. 1, the multiflexing is executed under the lower tensioning by POI because of the lower strand-tensioning caused by POI at the flexings than by P02, such lower stresses providing greater freedom of the strands for their relative shifting balancing movements during the multi-flexing. Theaxial tensioning between CD and the first exing at I, desirably low as above, of course is much lcss when the multi-flexing is executed under the pull by POI than when under the more powerful pull by P02, as is desirable in avoiding 'premature deformation.

Thus, for the purpose of effecting balanced relations and inert condition in a wire rope having a hemp-rope or fiber core; (1) the Wire rope treated is preferably one having substantially the non-inert condition of the ordinary type as emerging from CD, (2) the rope is subjected successively to a plurality of tensionings preferably also (3) including flexings preferably (4) under the tensioning of POI and'preferably (5) as early as practicable after emergence from CD and preferably (6) under stressings of progressively increasing magnitude, in order to effect the balancing and inertness while avoiding premature deformation opposing desired balancing and yet effecting substantial inertness simultaneous with the balancing treatment as a whole; the ultimate deepness of the core-grooves corresponding with both the objectives of strand-inertness and balanced relations of strands to core, for' the deeper the core-grooves produced by multi-flexing the better the relations of balance between strands and the commercial irregular. fiber core; the balanced relations of strands to strands being effected largely by the earlier, less heavy stresses before optimum strand-deformation by the cooperation of the greater core-resistance and higher strand-tensionings of the later, heavier tensionings. Greater deformations and inertness in a wire rope having a fiber core are producedl by the successive treatments of Fig. 1 including the multi-flexing between CD and POI and the higher tensioning by P02, the latter as shown preferably being, when used, in continuous process with the multi-flexing to avoid intermediate handling; and the greater strand-deformation in any case resulting from the combination of the later heavier strand-tensionings together with the higher core-resistance to strand-compressions on the core by such heavier strandtensionings.

Results similar to those of the processings of Fig. 1 are produced by the different form of successive stressings diagrammed in Fig. 10 which includes the succession of progressively increasing tensionings of Fig. 1 but without the ilexings between CD and POI; the first step in Fig. 10 being the axial tensioning between CD and POI upon the wire rope in its condition of emergence from CD, such tensioning being low relative to the subsequent tensioning by P02, and such later, higher tensioning by P02 being the other step of the series of stressings of progressively increasing magnitude; P02 being any powerdriven drum such as has been used heretofore to pull wire-rope structures assembled in CD from CDto the shipping-reel or wind-up reel at right, Fig. l; the drum or drums P02 of course being driven at the rate producing the desired tensioning higher than POI. In Fig. 10, when the wireassembly treated includes a fiber core, each tensioning step produces results in balancing and deformations of strands and core similar in kind to those of the flexings and tensionings oi Fig. 1; but the flexings under the tensionings in Fig. 1 are more eiiective in producing the ironing and kneading operations. But as the effect of the higher tensioning as by P02 in Figs. 10 and 1 than by POI in Fig. 1, the total strand-deformation by POI and P02 can be made greater than by POI alone without P02. The higher tensioning by P02 causes more powerful strand-compressions on the core and they cause greater( strand-deformations against great radial resistance of center or core regardless of core-material. When desirable in the case of any wire rope structure to employ more than the two successive tensioning steps diagrammed in Fig. 10, similar to the series of three successive tensionings cansing the three flexings in Fig. 1 and for the similar purpose of producing better balancing in a given product, then a third power-driven pull-ou may be located in Fig. to receive the assembled wire structure traveling from POI toward P02, and driven at a rate causing its ropetensioning to be higher than POI but lower than P02, in analogy to the progressively increasing magnitude-of the steps of tensioning in Fig. 1, and in accord with the general principle of the invention of avoiding premature strand-deformation which would prevent desired balancing. In any case when the tensioning by the last drum, as P02, may be so high as possibly to affect adversely the operations in the preceding steps including assembling in CD, then such adverse effect can be prevented if desired by employing an ordinary snubbing drum SD with usual brake BK, which may be used even in addition to the employment of POI in the form as shown of the common multiple-groove, double drum, wire rope pull-out.

In Fig. 10 the application of the tensioning by P02 as a continuous process with the assembling in CD and with the tensioning of the assembly between CD and POI, is even more desirable than is the continuity of tensioning in Fig. 1 by P02 with the multi-flexing between CD and POI, because in Fig. 10 there is less strand-deformation by the lower tensioning between CD and POI than in Fig. 1 between 3 and POI, and the higher tensioning by P02 is useful in Fig. 10 in effecting sufllciently great strand-deformation to produce sufficient inertness to withstand handling.

For wire rope structures of the many previously existing different designs of the helical outer elements and of the various resilient materials for the center or core, and for wire rope 'structures designed as to dimensions to be adapted for various different kinds of service, the particular modes of applying our processing stresses of ironing, tensioning or flexing, or both, illustrated in the drawings by way of example, may be widely varied; and this applies also to the length of time of continuous application of a processing stress vto the wire-rope assembly, as well as to the number of times processing stresses may be applied in succession to a wire rope structure of any given design, and also to the intensity of' the applied processing stress or stresses.

The wire-helix deformation effected by the heavier assembly-stressings hereof, with or without flexing and irrespective of core-material, are suflicient to produce the desired inert characteristic in wire rope structures. The ultime deformation of these outer helical elements of the assembly is illustrated in Figs. 3 and 9 by the wire-helix EV 'of substantial diameter as con- P illustrates the helices of substantially greater di' ameter resulting from our processing. It is this increase of metal-set helix-deformation which marks the difference between the lack of inertness of the ordinary type as heretofore'constructed, and on the other, the product of the processing hereof possessing ample inertness.

Although helix EV is of much larger Adiameter than helix A, yet it is much smaller than helix B. Helices A and EV illustrate wire rope strands which have been removed from assembledwire rope structures, helixI A -having been removed from the ordinary type in its condition of emergence from CD, Figs. 1 and 10, and helix EV having been removed from one ofour products, as Figs. 2 or 8, in their condition on drum POI Fig. 1, or on drum P02 of Fig. 10, or on drum P02 of Fig. 1. Each of helices A and EV before removal from their wire ropes was in the form at B, Fig. 9, i. e., of a diameter corresponding generally with that of the core. Upon their removal from their cores, however, helices A and EV have sprung back to their natural, inherent metal-set shapes. The lack of inertnessof an ordinary Wire rope is due to its inclusion of helices shaped to no greater helical diameter than A. In our production of the improved ordinary type including helices like EV, the helical diameter is ample for rope-inertness, especially with the cooperation of the permanently deformed deep core grooves G G when the assembly treated includes a center having the initial radial yieldability of a fiber core. By the processing hereof therefore, we retain the advantageous lack of excessive springiness which characterizes the ordinary type, while at the same time we obtain an ample extent of the inertness of the preformed type, to eliminate the excessive susceptibility to rope-faults which heretofore has` characterized the ordinary type.`

The above deformed strands EV and groovedeformed cere in Figs. 3 and 5 respectively, are shown combined in assembly in Figs.l 2 and 8 in wire ropes having fiber coreswhich constitute the larger percentages of wire rrope structures.

In Figs. 2 and 8 also are shown the ideal or balanced relations of strands to strands. and of strands to core, as well as such relations can be illustrated by drawings, and especially by a crosssection. The fact is that the balanced relations produced by the processing' hereof exist not merely at occasional cross-sections of the processed rope as in Figs. 2 and 8, but they exist continuously throughout itslength, because all of the processing stresses are applied, in succes'- sion, to each and every portion of the ropelength as it travels through the successive stages of the process from CD. In the multi-flexing process of Fig. 1 this is particularly the case because said multi-flexing preferably is'a process which as a whole is a step/of aprocess continucus withthe operation of assemblage in. CD, because the actions includedA in the multi-flexing preferably include the interactions between CD and the relatively small sheaves which are involved in the above relative longitudinal shifting strand-movements between CD' and sheav'e I which constitute the initial-ironing-back operation of vthe balancing treatment. Upon the ironing out of strand-slacks, the flexing stresses are applied in rapid succession to the same portion of the rope-length, so that all' portions of ropelength are in symmetrical balanced relations as shown in Figs. 2 and 8. Thus thereby is balancing effected atall portions of the length of the treated wire rope, and the sections of Figs. 2 and` 8, showing the actual, ideal, symmetrical relations of strands'tostra-nds and of vstrands to core, atv one particular cross-section of the'rope, lserve vto illustrate the conditions throughout theA length oi' the wire rope. Fig. 6 'shows thecore R of a wire rope of Fig, 2 which has been subjected to long service throughout the normal longitudinally resilient life of the core and has survived that serv-v ice without injury as the result'of the balanced and inert (deformed) strands and core. This is indicated in Fig. 'I by the fact that, although as the result of the 'long service the gore-grooves. have become much deeper than those of the core of our perfected product in Figs. 2 and 5, as an accompaniment of the loss of longitudinal resilience during the long service, nevertheless such'. groove-deepening ghasA continued symmetrically with the grooves GG in Figs. 2 and 5. Fig. 7 in elevation illustrates the same wire rope after the same long service, this figure showing the continued maintenance of the strands after long service free from development of rope-faults into injuries.

A criterion of an effective" execution of the processing hereof may be either a wire rope havying .the novel constructions hereof, or a wire rope of the ordinary` type as above and not having the previous characteristic inertness and nonbalanced relations.

We have discovered that the above principal the nature of the process and product is such /as to-permit the use of a larger corel than herer For-y example, as. to the highest or last.

tofore. stressing, as by P02. This higher axialA tension", noted on Fig. 10, usefully may be much greater than is possible by any-arrangement for assembling-in CD without injury to thev helical f outer wires by diecompression by CD on the travcling assembly; and this highest tensioning-by P02. in Figs. 1 and 10, preferably, for effective metal-set helix-deformation, is atleast a substantial fraction of the breaking-strength or maximum service load for which any particular form of structure which may be in process of fabrication, was-intended,` andl designed andv adapted. In some casesv the highest of these higher tensionings may be equal vte or even may exceed the 0 tensioning by the maximum service -load for which a particular structure may have been designed. 'Ihe values of this 'highest tensioning hereof are defined `even more precisely by the following illustrationof a structure designed to i .three to five toria-about, say, fifteen per cent or more ci said assumed breaking strength of the particular structure assumed for illustration. A terisioning even as low as such a small but subsi'antial fraction of the breaking strength of the structure is high as compared with the closing tension acting on the saine assembly inside CD. But this highest tensioning by P02, without injury to the assembled structure, and `without causing alterations of the assembling operation inside CD, may be even higher than the above, Such as several times higher than even that smaller fraction (fifteen per cent) of the breaking strength of the structure.

In fact, we have discovered that the highest tensionings hereof, as by P02, may be so high as to approximate half the breaking strength of the structure without impairing its longitudinal resilience needed for service. In general, however, these highest tensionings Vmay be varied in value according to the grade and construction of the particular form of wire rope structure being processed according to the invention, and according to the service requirements of any such form; and, in general, in practice, the highest tensionings do not exceed the maximum stresses intended to be applied to the structure in service.

We claim:

1. The improvement in apparatus for making a wire rope-structure consisting of ilexibie but stiff lwire helices and a yieldable but radially resistant fiber-rope core, which includes, in combination with the closing die, the closing pull-out and the receiving apparatus, a second power-driven rotatable tensioning pull-out and a snubber therefor, both located between the first pull-out and the receiving apparatus; and a plurality of sheaves located between the closing die and the closing pull-out and constructed and arranged to apply a plurality of powerful bending stresses to the rope-structure at closely successive poriions of its length, as it travels from the closingdle to the closing pull-out.

2. In a wire rope machine, a source of supply of wire rope, a draw-off drum for the wire rope, a second draw-off drum for the wire rope positioned between the source of supply of Wire rope and the other drum, and means for rotating the drums, the rst mentioned drum tensioning the wire rope in'appreciably greater amount than the other drum. -v

3. In a wire rope machine, wire rope closing means, a draw-ofi drum for the Wire rope, a second draw-off drum for the wire rope positioned between the closing means and the other drum, and means for rotating the drums, the rst mentioned drum tensioning the wire rope in an appreciably greater amount than the other drum.

4. In an apparatus for the manufacture of wire rope structures having a plurality of substantially stiff but flexible outer wire elements bent into place at the squeezer onto and around a center element into helical shapes and thereby slightly deformed into metal-sets of small helical diameter, said apparatus being of the type including the lay-plate and squeezer in relatively rotatable relations, and including the closing pull-out causing said bending and slight metal-set deformation the squeezer, and including the wind-up reel receiving the completed rope-structure, the improvement which includes a second power-driven pull-out located in the rope-path between the closing pull-out and the wind-up reel, and pulling the assembled rope-structure at a higher rate and corresponding tension more powerful than the closing pull-out. thereby substantially increasing the comparatively small metal-set diameter of the helices as deformed by the squeezer, and consequently decreasing their tendency to unravel away from the center element.

5. An improved wire rope structure having a plurality of substantially stiff wire elements flexed around a center element into helices, and of the type characterized by having excessive tendency to unraveling resulting from the formation of its helices by flexingl at the squeezing die onto and around the center element, the improved rope-structure lacking such excessive tendency by virtue of the fact that its helices have a metalsct diameter substantially larger than that of their initial metal-set deformation effected by the squeezer.

6. An improved form of ordinary wire rope comprising a plurality of substantially stiif helical strands each comprising a plurality of helical wires stranded together, and a ber rope core, to inequalities of which the helical strands are adapted as characteristic of the productionmethod of ordinary Wire rope consisting in forming the helices by bending them into the core, the improved form however, lacking the excessive unraveling tendency characteristic of prior forms of ordinary rope by virtue of the fact that its helices have a metal-set diameter substantially larger than that of their initial metal-set deformationv by the squeezer in said characteristic production-method of ordinary wire rope.

'7. The improvement in the manufacture of wire rope structures of the type including a plurality of substantially stiff outer wire elements flexed into place onto the center element by the squeezer into helices, said improvement consisting in subjecting the rope-structure, subsequent to its assembly by such flexing at the squeezer, and during its travel from the closing pull-out to the wind-up reel, progressively to a powerful pulling and axial tensioning which deforms the stiff outer wire helices into metal-set helices of substantially larger diameter than the helical metal-set oi the initial deformation by thc squeezer. l

8. In an apparatus for the manufacture of improved ordinary wire rope structures, the combination with apparatus for bending the outer wire elements into place onto and around a center element into helical shapes, said apparatus including a squeezer and closing pull-out; of a wind-up reel and a second power-driven pullout between the wind-up reel and the closing pull-out and subjecting the rope structure to higher axial tension than the closing pull-out; and a plurality of sheaves of small diameters in closev succession between the squeezer and the closing pull out and offset from one another, for subjecting each portion of the travelling ropestructure to a rapid succession of sharp bendings in diiferent directions at long rope-arcs, constitutingr a kneading treatment putting the 'rope-elements in balanced stress-relations with one another before the rope-structure travels beyond the closing pull-out to the field of more powerful action of said second power-driven pullout.

9. In an apparatus for the manufacture of improved ordinary wire rope structures, the combination with apparatus for bending the outer wire elements into place onto and around a center element in helical shapes, said apparatus including a squeezer and a closing pull-out; of a Wind-up reel and a second power-driven pullout between the wind-up reel and the closing pull-out and subjecting the rope structure to higher axial tension than the closing pull-out, setting the elements in conditions'substantially eliminating tendencies to unraveling; and kneading means between the squeezer and closing pullout and working the rope-elements together into balanced stress relations with one another be.- fore the rope-structure is acted on by the higher tension of said second pull-out whereby when the latter sets the elements it sets them in the balanced stress relations eiectuated by said kneading means.

10. In the manufacture o ordinary vwire rope structure, the method of treatment after the bending of its outer wire elements by the squeezer onto thecenter element into helices, which consists in subjecting the rope to an axial tensioning so high that the metal-set of the helices by the squeezer is further deformed into a substantially larger metal-set helical diameter substantially reducing the unravelling tendency of the rope structure, and in subjecting the rope structure, previous to the application of said high tensioning and under a condition of lower tensioning, to a kneading and ironing treatment which puts the rope-elements in balanced stress relations with` one another, whereby when they thereafter are set by said higher tensioning they are set in said balanced stress relations effectuated by said kneading and ironing treatment.

11. The improved form of ordinary wire rope characteristically having its plurality of multiwire strands and its ber core in unbalanced stress relations with one another, and its strandhelices so insecurely set as to possess excessive tendency to unravel, the strand-helices of said improved form having an abnormally large deformed metal-set helical diameter not practicable to be effected by the initial bending of the strands helically onto the core, which large metal-set diameter of the strands sets them securely in a condition of substantial reduction of said unraveling tendency; and said abnormally large deformed metal-set helical diameter being substantially smaller than `the actual diameter of the helices as they extend around the core whereby the helices so-securely set are in balanced stress. relations to one another and the fiber core.

12. The improved form of ordinary wire rope structure, which like prior forms of the same, has a metal-set helical diameter of its outer wire elements which is substantially less than the acytual helical diameters of the elements extending around the core and which metal-set diameter is characteristic of the formation of the strands of ordinary wire lrope structures'by being bent directly onto the core into helices and which causes the undesirable excessive unravelling tendency of ordinary wire rope structures and causes the desirable adaptation of the helices to inequalities of the core; the metal-set helical diameter of the helices of the improved form of ordinary rope being substantially greater than prior forms thereof, namely, greater than is practicable to be effected by the squeezer, causing substantial decrease of the undesirable unravelling tendency, and substantial increase of the desirable adaptation of the helices to inequalities of the core.

13. The improvement upon ordinary" wire rope structures wherein the multiple-wire helices tend powerfully to straighten out and cause unravelling, owing to the bending of the wire elements onto the center element into helices instead of pre-forming the helices before assembly with said center, said improvement consisting of a. condition of the wire-helices which substantially reduces their tendency to straighten out and cause unravelling, said condition being Ya metal set of said helices in substantially larger diameters than is practicable to be effected by said bending onto the center.

14. The improved form of ordinary wire rope structure which vconsists of a permanent setting of the elements in a condition substantially decreasing the excessive tendency to unravelling which is characteristicof previous forms of the ordinary type, and substantially improving the unbalanced stress relations which are characteristic of such previous forms, said setting being substantially dependent for said improvements,

upon the novel condition of the wire-helices in a substantially large metal set diameter which is substantially intermediate their straight metal set condition before assembly with the center element, and their actual helical diameter as they extend about the center in the rope structure, said metal-set diameter being larger than is practicable to be effected by the squeezer.

15. The improved form of "ordinary wire rope structure which consists fundamentally of a metal setting of the wire-helices in a helical d1- ameter substantially larger than is practicable to be effected by lbending into helices onto the center at the squeezer, but substantially smaller than the actual diameter of the helices as they extend around the center element; said relatively great size of said diameter substantially decreasing the tendency to unravelling of prior forms of the ordinary" type; said relatively small size of said diameter preserving that lack of excessive setting which is characteristic of ordinary wire rope structures by which the wire elements can vbe adapted to inequalities of the center; and lsaid metal set diameter. being accompanied by balanced stress relations of the wire-helices with one another and the center as the result of its said relative smallness -of helical diameter and consequent lack of over-setting.

16. A wire rope structure of the ordinary type but improved by the feature of having its helical elements metal-set into substantially increased diameter beyond that practicable to be effected by bending into helices onto the center at the squeezer, which increased diameter substantially reduces the tendency to unravelling heretoforepossessed by ordinary" wire rope structures, and further improved by the feature of the helical elements being in balanced stress relations to one another and to the center elements,

and yet further improved by the feature of the helices and center being permanently set in their said balanced stress relations by means of said metal-set diameter of the helices.

17. As an improvement over both pre-formed wire rope structures and previous forms of ordinary wire rope structures, the product consisting of multiple-wire helices laid and closed on a liber core, and wherein the helices and core are .in balanced stress relations to one another and 18. The improvement in the manufacture of ordinary wire rope structures, which consists in subjecting such structure, after the bending of the wire elements onto the center element into helices, to a. plurality of powerful stressings successively applied, progressively increasing in power, successively causing smaller amounts of improvement in the balanced stress relations of the rope-elements, but successively causing greater amounts of improvement in the metal-set condition of the helices by'way of increases in the metal-set diameters of the helices; a later one of the stressing more securely setting the rope-elements in the balanced stress relations effected by the preceding stressing, than the preceding stressing itself. A

11,9. The improvementl in the manufacture of wire rope structure which consists in treating a rope structure of which the wire helices have been formed by bending them onto a center element` at the squeezer by subjecting such ropestructure as it travels away from the squeezer toward the wind-up reel to a powerful stressing which substantially improves the balanced stress relations of the rope-elements, and substantially increases the metal-set diameter of the wire helices, thereby substantially decreasing the unraveling tendency which is characteristic of the formation of the helices by bending the wire elements onto the center element.

20. The method of manufacturing an improved form of the type of wire rope structure which is produced by bending substantially stiff wire elements onto a center element by a squeezing die into helices, which consists in subjecting such rope structure to tensioning of a substantial fraction of the breaking strength' of the -structure and amounting to a pull of the order of tons, thereby effecting a substantial increase of the metal-set diameter of the helices above that effected at the squeezer, and effecting a corresponding decrease of the unraveling tendency characteristic of rope-structures having helices formed by bending onto the center element.

21. The method of manufacturing a wire rope structure of the type wherein the wire helices are formed by bending the wire elements onto the center element in the squeezer, and wherein the helices are substantially stiff, consisting of a multiplicity of wires stranded together, said method consisting in subjecting the rope-structure, subsequent to its assembly by such bending at the squeezer, and during its travel toward .the windup reel, to powerful tensioning deforming` its elements into a substantially increased metal-set diameter above the metal-set diameter effected by the bending at' the squeezer.

22. The improved wire rope structure of the type having substantially stiff wire elements formed into helices by being exed by a-squeezer onto a center element and thereby only slightly deformed, and having the characteristic feature of that type, of a tendency to unraveling, but lacking` the characteristic feature of that type heretofore, 'of unbalanced stress relations of the rope-elements, the improved rope-structure being characterized by a metal-set diameter of its helices substantially greater than that practicable to be effected by deformation at the squeezer, accompanied by corresponding decrease of the tendency to unraveling and by a decrease of the unbalanced stress relations of the rope-elements. 23. The method of manufacturing a wire rope structure having balanced stress relations of substantially stiff multiple-wire strands and a diametrically yieldable core, which consists in treating such a rope of which the strands possess only a small metal-set diameter, by subjecting it to a comparatively low pull increasing said small metal-set diameter to a not excessive extent; and subjecting the` rope structure so pulled to a powerful kneading treatment working the strands and core together back and forth under such low pull into balanced stress relations with one another, said kneading and balancing treatment being characterized by a rapid succession at each successive portion of the pulled rope, of sharp flexings at relatively long rope-arcs and in different directions. l

24. The improvement in apparatus for making comparatively stiff ordinary Wire rope sructures having a center of fiber rope and a plurality of substantially stiff but flexible outer wire elements bent into place onto the rope center vinto helices, said apparatus being of the type including the lay-plate and the squeezer in relatively rotatable relations, and the closing pull-out causing said bending of the stiff wire elements at the squeezer; and said improvement including a plurality of sheaves arranged for successive operation on the assembled rope-structure being pulled from the squeezer and then having unbalanced stress relations of its elements, said operation constituting a kneading and Working together of the stiff wire elements and ber rope center into balanced stress relations with one another, said plurality of sheaves being substantially dependent for their said kneading effect upon and including (1) an oli-setting of the sheaves from one another providing for long peripheral arcs of contact with the traveling ropestructure, (2) comparatively small diameters of the sheaves providing for relatively sharp bendings of the traveling rope-structure at such long contact-arcs, and (3) a substantially close succession of the sheaves providing for rapidly successive action upon each successive portion of the traveling rope-structure; said olf-setting providing also for successive bendings in different directions, all whereby each portion of the stiff traveling rope-structure is subjected to a rapid succession of sharp bendings in different directions at long rope-arcs, constituting the kneading operation by said arrangement of sheaves which balances the rope-elements.

25. The improvement in the manufacture of wire rope structures of the type including a plurality of substantially stiff yet flexible outer wire elements bent into place onto the center element by a squeezer into helices, said improvementl consisting in subjecting the rope-structure, subscquent to its assembly by such bending at the 4squeezer and during its travel away from the squeezer toward the wind-up reel, progressively to powerful stressing deforming its elements to a' substantial extent greater than is possible at the squeezer, including the deformation of the helices to a metal-set diameter substantially larger than that possible at the squeezer.

WALTER VOIG'ILANDER. MAHLON G. ENSINGER. 

